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BURNER WILL NOT FIRE
Possible Causes:
- Pilot not burning.
Main gas valve solenoid coil burned out.
- Water level too low or no water in sight glass.
- Honeywell operating pressure switch defective.
- Broken wire in burner circuit.
- Loose or broken probe in water column.
- Scale build-up on probe and/or water column.
Corrective Action:
- Check the gas supply.
- Replace solenoid coil.
- Replace gas valve.
- Replace Honeywell operating pressure switch.
- Check wiring for loose or broken connection.
- Tighten or replace probe in water column.
- Clean or replace probe and/or water column.
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BURNER WILL NOT SHUT OFF
Possible Causes:
- Honeywell pressure switch not operating.
- Faulty operating mechanism on gas valve.
- Broken wire in burner circuit (shorted to ground).
Corrective Action:
- Replace Honeywell pressure switch.
- Replace gas valve.
- Check for electrical short circuit and repair.
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PILOT BURNER NOT BURNING OR WILL NOT STAY LIT
Possible Causes:
- Pilot burner orifice plugged or dirty.
- Ignition wire burnt or shorting out.
- Ceramic ignitor cracked or broken.
- Ceramic ignitor misaligned.
- Ram ignition module defective.
- Pilot solenoid valve not opening.
- Pilot regulator plugged or broken.
Corrective Action:
- Clean pilot burner orifice.
- Replace ceramic ignitor.
- Replace pilot safety relay.
- Re-align ceramic ignitor to the center of the pilot assembly.
- Replace ignition module.
- Replace pilot solenoid valve.
- Clean or replace pilot regulator.
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PRE-IGNITION OR POOR LIGHT OFF
Possible Causes:
- 1. Pilot in wrong location in relation to main burner.
- 2. Dirty main burner orifices.
Corrective Action:
- Clean pilot burner and orifice without enlarging.
- Locate pilot burner so that top of burner is 1/2” above and 1/2” to the side of main burner.
- Clean burner caps with drill bit. Consult factory for proper drill bit size. Caution: be careful to avoid any increases in orifice size.
- Adjust barometric damper in stack (See Fig 3). Check for collapsed stack or restriction in stack.
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PUMP NOT PERFORMING PROPERLY
Possible Causes:
- No water being supplied to suction side of pump.
- Plugged strainer screen.
- Check valves worn or leaking.
- Pump leaking at shaft.
- Pump out of adjustment.
- Air lock.
- Vapor lock.
Corrective Action:
- Clean lines connecting float tank to water jacket on 9.5, 10 & 15 HP models.
- Remove and clean pump intake strainer screen. Clean lines from water jacket to pump.
- Repair or replace check valves.
- Replace shaft seal and “O” ring in pump.
- Adjust pump impeller. (See pump adjustment)
- With pump running, carefully loosen hex nut on angle check valve to bleed air from system. Tighten hex nut when water starts escaping.
- If vapor lock is caused by leaking check valves, replace check valves. If vapor lock is caused by too high a temperature in the return tank, check all steam traps for proper operation and repair as required.
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PUMP MOTOR WILL NOT RUN
Possible Causes:
- Starter relay defective.
- Loose or broken probe in water column.
- Broken electrical connection.
- Motor burned out.
Corrective Action:
- Replace starter relay.
- Tighten or replace probe in water column.
- Check wiring for loose or broken connection.
- Repair or replace motor.
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MAKE UP JACKET OVERFLOWS
Possible Causes:
- Defective float valve.
- Vent pipe on boiler restricted or improperly installed.
- Blow-by through defective steam traps in system.
- Blow-by through check valves.
Corrective Action:
- Repair or replace float valve.
- Check vent pipe for obstructions. Vent should not be reduced to smaller size than vent connection outlet on boiler.
- Repair or replace faulty steam traps.
- Repair or replace check valves.
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POOR BOILER PERFORMANCE (Low steam pressure or slow recovery)
Possible Causes:
- Low water condition in boiler, burner does not fire until pressure drops below 40 PSIG.
- Insufficient fuel supply to burners.
- Defective operating pressure switch.
- Calcium deposits, (boiler scale) in water tube assembly.
- Soot formation on water tube assembly.
Corrective Action:
- See pump performance section.
- Clean burners. Have gas company check for proper meter and supply line size and for proper gas pressure.
- Replace operating pressure switch.
- Descale boiler or replace plugged water tube assembly.
- Remove soot from tubes by means of heavy-duty commercial type vacuum cleaner. Have gas company check for improper combustion.
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SIGHT GLASS GASKETS LEAK
Possible Causes:
- Shut boiler down and allow to cool down.
- Gaskets deteriorated.
- Fittings improperly aligned.
Corrective Action:
- Shut boiler down and allow to cool down.
- Replace gaskets.
- Loosen nuts, carefully align sight glass fittings and tighten nuts.
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ADJUSTMENT OF WATER PUMP
WHEN TO ADJUST:
When boiler steam pressure drops to #60 before water can be pumped into the boiler.
- Loosen cap screw (Item 1) and drop holding clip (Item 2) out of collar (Item 3).
- Draw a pencil mark from collar (Item 3) onto motor casting (Item 4).
- Rotate collar clock-wise (NOTE: Collar is left-hand thread) until pencil marks are ¼” apart.)
- Remove dust guard (Item 5) from opposite end of motor. Then using a punch of piece of wood, tap the shaft (Item 6) lightly with a hammer to loosen the bearings so they can move forward.
- Replace dust guard (Item 5) and holding clip (Item 2) and tighten cap screw (Item 1).
Pump is now ready to use. Occasionally it may be necessary to go through the procedure a second time.
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